Headgear for First Responders

ABSTRACT

A face seal ( 12 ) for a respirator mask ( 10 ) includes an integrated strap ( 14 ) with a buckle ( 16 ). The integrated strap ( 14 ) is overmolded onto the buckle ( 16 ) to secure the buckle ( 16 ) to, and at least partially within, the strap ( 14 ). A respirator mask ( 10 ) includes a body ( 18 ) and a face seal ( 12 ). A method of manufacturing a face seal ( 12 ) for a respirator mask ( 10 ) includes overmolding a material of at least a portion of an integrated strap ( 14 ) onto a body portion ( 38 ) of a buckle ( 16 ) such that a head portion ( 36 ) of the buckle ( 16 ) is exposed from the integrated strap ( 14 ), the buckle body portion ( 38 ) including a plurality of structural features ( 46 ) that enhances bonding between the buckle body portion ( 38 ) and the overmolded material.

TECHNICAL FIELD

The present invention relates to personal protective equipment, and inparticular to a method and a face seal having straps that allowattachment of the straps to other elements of personal protectiveequipment.

BACKGROUND

Personal protective equipment masks, such as respirator masks are usedin environments where individuals are exposed to hazardous materials,such as gases, vapors, aerosols (e.g., dusts, mists, and/or biologicalagents), and/or the like. Respirator masks come in a large variety oftypes and sizes, ranging from cheaper, disposable masks to higher cost,reusable masks that include replaceable filtration cartridges. Mostrespirator masks include a face seal that seals against the user's face.For example, face seals may include flexible lips, gaskets, cushions,and/or the like that engage in physical contact with the user's face tocreate the seal.

A face seal typically includes one or more integrated straps that can beattached to additional straps for securing the mask to the user's head.For example, the integrated straps may be connected to a harnessconfigured to hold the mask to the user's head. However, the integratedstraps are made of the same flexible material as the face seal, and itmay be difficult to achieve a secure connection between the face sealstraps and the additional straps.

Additionally, currently known face seals include straps that have holesor apertures within the straps, which provide means for attachment tothe additional straps. However, including such a hole in the strap maycompromise the structural integrity of the flexible strap.

Finally, using connection mechanisms such as buckles increases thethickness of the face seal straps and/or the additional straps, whichcan be uncomfortable to the user when the mask is used with a helmet,hood, and/or other headgear and/or other items of personal protectiveequipment.

SUMMARY

The present invention advantageously provides a method and face seal forsecurely attaching the face seal of a respirator mask to a harness orother straps for securing the respirator mask to a user's head. In oneembodiment, a face seal for use with a respirator mask includes anintegrated strap and a buckle, the integrated strap being overmoldedonto at least a portion of the buckle.

In one aspect of the embodiment, the buckle includes a body portion anda head portion, the body portion being within the integrated strap. Inone aspect of the embodiment, the buckle body portion includes at leastone aperture, a first at least substantially planar surface, and asecond at least substantially planar surface opposite the first at leastsubstantially planar surface, the at least one aperture extendingbetween the first and second at least substantially planar surfaces.

In one aspect of the embodiment, the integrated strap is composed of afirst material and the buckle is composed of a second material, thefirst material being overmolded onto the second material such that thefirst material extends through the at least one aperture.

In one aspect of the embodiment, the body portion includes a pluralityof ridges. In one aspect of the embodiment, the buckle body portionfurther includes a first lateral surface and a second lateral surfaceopposite the first lateral surface, the plurality of ridges including afirst set of ridges on the first lateral surface and a second set ofridges on the second lateral surface, each of the first and secondlateral surfaces being located between the first and second at leastsubstantially planar surfaces.

In one aspect of the embodiment, the integrated strap includes alongitudinal axis, each of the plurality of ridges including a surfacethat extends from the longitudinal axis in a direction that is at leastsubstantially orthogonal to the longitudinal axis. In one aspect of theembodiment, the surface of each of the plurality of ridges is a firstsurface, each of the plurality of ridges further including a secondsurface that extends from the longitudinal axis in a direction that isat an angle of less than approximately 90° to meet the first surface.

In one aspect of the embodiment, the integrated strap and the face sealare composed of the first material.

In one aspect of the embodiment, the second material has a greaterdurometer than the first material.

In one aspect of the embodiment, the integrated strap has a maximumthickness of no more than 0.2 inches.

In one embodiment, a respirator mask includes: a body; and a face sealcoupled to the body, the face seal including: at least one integratedstrap; and at least one buckle, the at least one integrated strap beingovermolded onto at least a portion of a corresponding one of the atleast one buckle.

In one aspect of the embodiment, the at least one buckle includes a bodyportion and a head portion, the at least one integrated strap beingovermolded onto the body portion of the corresponding one of the atleast one buckle.

In one aspect of the embodiment, the body portion includes at least oneaperture.

In one aspect of the embodiment, the body portion includes: a first atleast substantially planar surface and a second at least substantiallyplanar surface opposite the first at least substantially planar surface;and a first lateral surface and a second lateral surface opposite thefirst lateral surface, the first and second lateral surfaces beingbetween the first and second at least substantially planar surfaces.

In one aspect of the embodiment, the body portion further includes: aplurality of apertures extending between the first and second at leastsubstantially planar surfaces; and a first set of ridges on the firstlateral surface and a second set of ridges on the second lateralsurface.

In one aspect of the embodiment, the integrated strap includes alongitudinal axis, each of the plurality of ridges including a surfacethat extends from the longitudinal axis in a direction that is at leastsubstantially orthogonal to the longitudinal axis. In one aspect of theembodiment, the surface of each of the plurality of ridges is a firstsurface, each of the plurality of ridges further including a secondsurface that extends from the longitudinal axis in a direction that isat an angle of less than approximately 90° to meet the first surface.

In one aspect of the embodiment, the integrated strap has a maximumthickness of no more than 0.2 inches.

In one embodiment, a method of manufacturing a face seal for arespirator mask, the face seal having at least one integrated strap,includes: positioning a buckle within a mold for the face seal such thatthe buckle is located at a distal end of the at least one integratedstrap, the buckle being composed of a first material, the buckle havinga head portion and a body portion, the body portion having at least oneaperture and a plurality of structural features; and overmolding asecond material onto the buckle body portion such that the buckle headportion is exposed from the distal end of the at least one integratedstrap and the second material flows through the at least one apertureand around the plurality of structural features, the plurality ofstructural features being configured to retain the buckle body portionwithin the at least one integrated strap.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention, and theattendant advantages and features thereof, will be more readilyunderstood by reference to the following detailed description whenconsidered in conjunction with the accompanying drawings wherein:

FIG. 1 shows a front perspective view of a respirator face mask having aface seal and integrated straps with buckles;

FIG. 2 shows a perspective view of an end portion of an integrated straphaving a buckle;

FIG. 3 shows the perspective view of FIG. 2, with an internal portion ofthe buckle visible through the integrated strap; and

FIG. 4 shows a flow chart for an exemplary method of manufacturing aface seal.

DETAILED DESCRIPTION

The invention advantageously provides a face seal for an item ofpersonal protective equipment, such as a respirator mask, that has atleast one integrated strap with a buckle. Each integrated strap isovermolded onto the buckle to secure the buckle to, and at leastpartially within, the strap. Each integrated strap is relatively thin(as compared with known straps), thereby giving the integrated strap alow profile that enhances user comfort when the respirator mask is wornbeneath a helmet, hood, and/or other headgear and/or with another itemof personal protective equipment.

Before describing in detail exemplary embodiments that are in accordancewith the disclosure, it is noted that components have been representedwhere appropriate by convention symbols in drawings, showing only thosespecific details that are pertinent to understanding the embodiments ofthe disclosure so as not to obscure the disclosure with details thatwill be readily apparent to those of ordinary skill in the art havingthe benefit of the description herein.

As used herein, relational terms, such as “first,” “second,” “top” and“bottom,” and the like, may be used solely to distinguish one entity orelement from another entity or element without necessarily requiring orimplying any physical or logical relationship or order between suchentities or elements. The terminology used herein is for the purpose ofdescribing particular embodiments only and is not intended to belimiting of the concepts described herein. As used herein, the singularforms “a”, “an” and “the” are intended to include the plural forms aswell, unless the context clearly indicates otherwise. It will be furtherunderstood that the terms “comprises,” “comprising,” “includes” and/or“including” when used herein, specify the presence of stated features,integers, steps, operations, elements, and/or components, but do notpreclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which this disclosure belongs. It willbe further understood that terms used herein should be interpreted ashaving a meaning that is consistent with their meaning in the context ofthis specification and the relevant art and will not be interpreted inan idealized or overly formal sense unless expressly so defined herein.

Referring now to the drawing figures in which like referencedesignations refer to like elements, an embodiment of a respirator maskfor providing respiratory protection that includes a face sealconstructed in accordance with the principles of the invention is shownin the figures and generally designated as “10.” Referring to FIG. 1,the mask 10 is a respirator mask configured to be worn by a user inenvironments where the user is exposed to hazardous materials, such as,but not limited to, gases, vapors, aerosols (such as dusts, mists,and/or biological agents), and/or the like. The mask 10 includes a faceseal 12 having integrated straps 14 with buckles 16. Integrated as usedherein means that the face seal 12 is manufactured to include the straps14, such as by molding the face seal 12 and straps 14 as a singleintegrated piece. Thus, the straps 14 are extensions of the main portionof the face seal 12. The mask 10 includes other components, depending onthe conditions and purpose for which the mask 10 is used. As anon-limiting example, the mask 10 generally includes a body 18, afaceplate or fenestra 20 with an aperture 22 to which a respirator canbe attached (not shown), and a nosecup 24 within the interior of themask 10.

The body 18 is composed of any suitable material(s), such as a rigid orsemi-rigid plastic. The face seal 12 may be attached to the mask bodysuch that the face seal 12 is configured to create a seal around atleast a portion of the user's face when the mask is worn (e.g., theuser's mouth and nose). The face seal 12 and integrated straps 14 may becomposed of a material having a lower durometer than the body 18. As anon-limiting example, the body 18 may be composed a rigid plastic, suchas high-density polyethylene (HDPE), whereas the face seal 12 andintegrated straps 14 may be composed of silicone rubber, thermoplasticelastomer (TPE), rubber (either natural or synthetic), and/or othermaterial that is more flexible than the body 18. Although FIG. 1 showsall of the integrated straps 14 having overmolded buckles 16, it will beunderstood that fewer than all of the integrated straps 14 may includeovermolded buckles. For example, the integrated strap 14 that ispositioned over the user's forehead during use may include theovermolded buckle 16, whereas the other integrated straps 14 may includedifferent means for attachment between the straps 14 and harness straps.Also, the invention is not limited to the quantity of straps shown inthe drawing figures. It is contemplated that fewer or more straps thanare shown may be implemented.

Referring now to FIGS. 2 and 3, the integrated straps 14 and buckles 16are shown in more detail. Each integrated strap 14 generally includes afirst or proximal end 30 and a second or distal end 32 opposite theproximal end 30. The first end 30 is the portion of the strap 14 thatmeets the main portion of the face seal 12. The second end 32 includesthe buckle 16. During manufacture, the strap 14 is overmolded onto thebuckle 16. Overmolding processes are known in the art and are beyond thescope of the instant disclosure. The buckle 16 is composed of one ormore rigid materials, such as metal, plastic, HDPE, or other suitablematerial that will not fracture or break when tension is exerted on thebuckle during use, such as by the additional strap that is attached tothe buckle 16.

As shown in FIG. 3, the buckle 16 includes a head portion 36 and a bodyportion 38. The head portion 36 is exposed from the strap 14 andincludes an aperture 40 through which an end of an additional strap,such as a harness strap, may be passed to secure the additional strap tothe integrated strap 14. The body portion 38 includes one or morestructural features that facilitate or enhance bonding between the strapmaterial and the buckle 16 when the strap 14 is overmolded onto thebuckle 16. As a non-limiting example, in one embodiment the body portion38 includes a plurality of apertures 44 (in some embodiments, at leastone aperture 44) through which the strap material may flow during theovermolding process, and a plurality of ridges or teeth 46 that helpprevent the buckle 16 from being pulled from within the strap 14 when aforce is exerted on the buckle 16 in a direction away from the strapsecond end 32, such as may be exerted by a harness strap when the mask10 is in use. Further, the body portion 38 has a first at leastsubstantially planar surface 50 and a second at least substantiallyplanar surface 52 opposite the first surface 50. The apertures 44 extendall the way between the first 50 and second 52 surfaces. A first set ofridges 46 is located along a first edge or lateral surface 54 of thebody portion 38 between the first 50 and second 52 surfaces, and asecond set of ridges 46 is located along a second edge or lateralsurface 56 opposite the first edge of the body portion 38 between thefirst 50 and second 52 surfaces. The buckle 16 defines a longitudinalaxis 58 that is coaxial with the longitudinal axis of the strap 14, andeach set of ridges 46 extends along a distance that is parallel to thelongitudinal axis 54. Although the flow of the overmolded materialthrough the plurality of apertures 44 will help retain the buckle 16within the strap 14, the ridges 46 may be configured to further resistlinear movement of the body portion 38 within the strap 14 toward thestrap second end 32. In one embodiment, the ridges 46 are configuredlike barbs to help keep the buckle 16 in place, with each ridge 46having a first surface 62 that extends from the longitudinal axis 58 ina direction that is at least substantially orthogonal to thelongitudinal axis 58 and a second surface 64 that extends from thelongitudinal axis 58 in a direction that is at an angle of less thanapproximately 90° to meet the first surface 62.

In one embodiment, the body portion 38 may have a thickness such thatthe maximum thickness T_(max) of the strap 14 is approximately 0.2inches or less. This thinness of the strap, in addition to the softnessof the strap material, may reduce pressure exerted by the strap 14 andbuckle 16 on the user's head (for example, on the user's forehead) whenthe mask 10 is worn, and particularly when the mask 10 is worn withadditional headgear, such as a helmet, that may compress the strap 14and/or buckle 16 against the user's head.

Referring now to FIG. 4, an exemplary method of manufacturing a faceseal is shown. A face seal mold is used to create the face seal 12having at least one integrated strap 14. The mold may have, andtherefore the face seal 12 may be manufactured to have, any number ofintegrated straps 14. Further, all or fewer than all of the integratedstraps 14 may be overmolded onto a buckle 16. For simplicity, theexemplary method will be discussed as though the face seal 12 includes asingle buckle 16 in one of the integrated straps 14. In a first step100, a buckle 16 is positioned within the mold such that the buckle 16will be located at a second or distal end 32 of an integrated strap 14created by the mold. In a second step 102, a first material used tocreate the integrated straps 14 is poured into the mold such that it notonly forms the face seal 12 and integrated straps 14, but is alsoovermolded onto the buckle 16. Thus, the first material flows throughthe apertures 44 and around the ridges 46. As discussed above, thepresence of the first material within the apertures 44 and theconfiguration of the ridges 46 both help retain the buckle body 38within the strap 14. The face seal 12 is then removed from the mold andattached to an item of personal protective equipment, such as arespirator mask 10.

In one embodiment, a face seal 12 for use with a respirator mask 10includes an integrated strap 14 and a buckle 16, the integrated strap 14being overmolded onto at least a portion of the buckle 16.

In one aspect of the embodiment, the buckle 16 includes a body portion38 and a head portion 36, the body portion 38 being within theintegrated strap 14. In one aspect of the embodiment, the buckle bodyportion 38 includes at least one aperture 44, a first at leastsubstantially planar surface 50, and a second at least substantiallyplanar surface 52 opposite the first at least substantially planarsurface 50, the at least one aperture 44 extending between the first 50and second 52 at least substantially planar surfaces.

In one aspect of the embodiment, the integrated strap (14) is composedof a first material and the buckle (16) is composed of a secondmaterial, the first material being overmolded onto the second materialsuch that the first material extends through the at least one aperture(44).

In one aspect of the embodiment, the body portion 38 includes aplurality of ridges 46. In one aspect of the embodiment, the buckle bodyportion 38 further includes a first lateral surface 54 and a secondlateral surface 56 opposite the first lateral surface 54, the pluralityof ridges 46 including a first set of ridges 46A on the first lateralsurface 54 and a second set of ridges 46B on the second lateral surface56, each of the first 54 and second 56 lateral surfaces being locatedbetween the first 50 and second 52 at least substantially planarsurfaces.

In one aspect of the embodiment, the integrated strap 14 includes alongitudinal axis 58, each of the plurality of ridges 46 including asurface 62 that extends from the longitudinal axis 58 in a directionthat is at least substantially orthogonal to the longitudinal axis 58.In one aspect of the embodiment, the surface 62 of each of the pluralityof ridges 46 is a first surface 62, each of the plurality of ridges 46further including a second surface 64 that extends from the longitudinalaxis 58 in a direction that is at an angle of less than approximately90° to meet the first surface 62.

In one aspect of the embodiment, the integrated strap 14 and the faceseal 12 are composed of the first material.

In one aspect of the embodiment, the second material has a greaterdurometer than the first material.

In one aspect of the embodiment, the integrated strap 14 has a maximumthickness T_(max) of no more than 0.2 inches.

In one embodiment, a respirator mask 10 includes: a body 18; and a faceseal 12 coupled to the body 18, the face seal 12 including: at least oneintegrated strap 14; and at least one buckle 16, the at least oneintegrated strap 14 being overmolded onto at least a portion of acorresponding one of the at least one buckle 16.

In one aspect of the embodiment, the at least one buckle 16 includes abody portion 38 and a head portion 36, the at least one integrated strap14 being overmolded onto the body portion 38 of the corresponding one ofthe at least one buckle 16.

In one aspect of the embodiment, the body portion 38 includes at leastone aperture 44.

In one aspect of the embodiment, the body portion 38 includes: a firstat least substantially planar surface 50 and a second at leastsubstantially planar surface 52 opposite the first at leastsubstantially planar surface 50; and a first lateral surface 54 and asecond lateral surface 56 opposite the first lateral surface 54, thefirst 54 and second 56 lateral surfaces being between the first 50 andsecond 52 at least substantially planar surfaces.

In one aspect of the embodiment, the body portion 38 further includes: aplurality of apertures 44 extending between the first 50 and second 52at least substantially planar surfaces; and a first set of ridges 46 onthe first lateral surface 54 and a second set of ridges 46 on the secondlateral surface 56.

In one aspect of the embodiment, the integrated strap 14 includes alongitudinal axis 58, each of the plurality of ridges 46 including asurface 62 that extends from the longitudinal axis 58 in a directionthat is at least substantially orthogonal to the longitudinal axis 58.In one aspect of the embodiment, the surface 62 of each of the pluralityof ridges 46 is a first surface 62, each of the plurality of ridges 46further including a second surface 64 that extends from the longitudinalaxis 58 in a direction that is at an angle of less than approximately90° to meet the first surface 62.

In one aspect of the embodiment, the integrated strap 14 has a maximumthickness T_(max) of no more than 0.2 inches.

In embodiment, a method of manufacturing a face seal 12 for a respiratormask 10, the face seal 12 having at least one integrated strap 14,includes: positioning a buckle 16 within a mold for the face seal 12such that the buckle 16 is located at a distal end 32 of the at leastone integrated strap 14, the buckle 16 being composed of a firstmaterial, the buckle 16 having a head portion 36 and a body portion 38,the body portion 38 having at least one aperture 44 and a plurality ofstructural features 46; and overmolding a second material onto thebuckle body portion 38 such that the buckle head portion 36 is exposedfrom the distal end 32 of the at least one integrated strap 14 and thesecond material flows through the at least one aperture 44 and aroundthe plurality of structural features 46, the plurality of structuralfeatures 46 being configured to retain the buckle body portion 38 withinthe at least one integrated strap 14.

It will be appreciated by persons skilled in the art that the presentinvention is not limited to what has been particularly shown anddescribed herein above. In addition, unless mention was made above tothe contrary, it should be noted that all of the accompanying drawingsare not to scale. A variety of modifications and variations are possiblein light of the above teachings without departing from the scope andspirit of the invention, which is limited only by the following claims

1. A face seal for use with a respirator mask, the face seal comprising:an integrated strap; and a buckle, the integrated strap being overmoldedonto at least a portion of the buckle.
 2. The face seal of claim 1,wherein the buckle includes a body portion and a head portion, the bodyportion being within the integrated strap.
 3. The face seal of claim 2,wherein the body portion includes at least one aperture, a first atleast substantially planar surface and a second at least substantiallyplanar surface opposite the first at least substantially planar surface,the at least one aperture extending between the first and second atleast substantially planar surfaces.
 4. The face seal of claim 3,wherein the integrated strap is composed of a first material and thebuckle is composed of a second material, the first material beingovermolded onto the second material such that the first material extendsthrough the at least one aperture.
 5. The face seal of claim 3, whereinthe buckle body portion includes a plurality of ridges.
 6. The face sealof claim 5, wherein the buckle body portion further includes a firstlateral surface and a second lateral surface opposite the first lateralsurface, the plurality of ridges including a first set of ridges on thefirst lateral surface and a second set of ridges on the second lateralsurface, each of the first and second lateral surfaces being locatedbetween the first and second at least substantially planar surfaces. 7.The face seal of claim 5, wherein the integrated strap includes alongitudinal axis, each of the plurality of ridges including a surfacethat extends from the longitudinal axis in a direction that is at leastsubstantially orthogonal to the longitudinal axis.
 8. The face seal ofclaim 7, wherein the surface of each of the plurality of ridges is afirst surface, each of the plurality of ridges further including asecond surface that extends from the longitudinal axis in a directionthat is at an angle of less than approximately 90° to meet the firstsurface.
 9. The face seal of claim 4, wherein the integrated strap andthe face seal are each composed of the first material.
 10. The face sealof claim 4, wherein the second material has a greater durometer than thefirst material.
 11. The face seal of claim 1, wherein the integratedstrap has a maximum thickness (T max) of no more than 0.2 inches.
 12. Arespirator mask comprising: a body; and a face seal coupled to the body,the face seal including: at least one integrated strap; and at least onebuckle, the at least one integrated strap being overmolded onto at leasta portion of a corresponding one of the at least one buckle.
 13. Therespirator mask of claim 12, wherein the at least one buckle includes abody portion and a head portion, the at least one integrated strap beingovermolded onto the body portion of the corresponding one of the atleast one buckle.
 14. The respirator mask of claim 13, wherein the bodyportion includes at least one aperture.
 15. The respirator mask of claim13, wherein the body portion includes: a first at least substantiallyplanar surface and a second at least substantially planar surfaceopposite the first at least substantially planar surface; and a firstlateral surface and a second lateral surface opposite the first lateralsurface, the first and second lateral surfaces being between the firstand second at least substantially planar surfaces.
 16. The respiratormask of claim 15, wherein the body portion further includes: a pluralityof apertures extending between the first and second at leastsubstantially planar surfaces; and a first set of ridges on the firstlateral surface and a second set of ridges on the second lateralsurface.
 17. The respirator mask of claim 16, wherein the integratedstrap includes a longitudinal axis, each of the first and second sets ofridges including a surface that extends from the longitudinal axis in adirection that is at least substantially orthogonal to the longitudinalaxis.
 18. The respirator mask of claim 17, wherein the surface of eachof the first and second sets of ridges is a first surface, each of thefirst and second sets of ridges further including a second surface thatextends from the longitudinal axis in a direction that is at an angle ofless than approximately 90° to meet the first surface.
 19. Therespirator mask of claim 12, wherein the integrated strap has a maximumthickness (T max) of no more than 0.2 inches.
 20. A method ofmanufacturing a face seal for a respirator mask, the face seal having atleast one integrated strap, the method comprising: positioning a bucklewithin a mold for the face seal such that the buckle is located at adistal end of the at least one integrated strap, the buckle beingcomposed of a first material, the buckle having a head portion and abody portion, the body portion having at least one aperture and aplurality of structural features; and overmolding a second material ontothe buckle body portion such that the buckle head portion is exposedfrom the distal end of the at least one integrated strap and the secondmaterial flows through the at least one aperture and around theplurality of structural features, the plurality of structural featuresbeing configured to retain the buckle body portion within the at leastone integrated strap.